US20140083198A1 - Methods of validating edge strength of a glass sheet - Google Patents
Methods of validating edge strength of a glass sheet Download PDFInfo
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- US20140083198A1 US20140083198A1 US13/624,265 US201213624265A US2014083198A1 US 20140083198 A1 US20140083198 A1 US 20140083198A1 US 201213624265 A US201213624265 A US 201213624265A US 2014083198 A1 US2014083198 A1 US 2014083198A1
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
- G01N33/38—Concrete; Lime; Mortar; Gypsum; Bricks; Ceramics; Glass
- G01N33/386—Glass
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M5/00—Investigating the elasticity of structures, e.g. deflection of bridges or air-craft wings
- G01M5/0075—Investigating the elasticity of structures, e.g. deflection of bridges or air-craft wings by means of external apparatus, e.g. test benches or portable test systems
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/40—Investigating hardness or rebound hardness
- G01N3/54—Performing tests at high or low temperatures
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/60—Investigating resistance of materials, e.g. refractory materials, to rapid heat changes
Definitions
- the present invention relates generally to methods of validating edge strength and, more particularly, to methods of validating edge strength of a glass sheet.
- Glass sheets are component in products such as architectural and automotive windows, liquid crystal display (LCD) modules, and photovoltaic (PV) panels.
- a glass sheet is typically cut to size, and then resulting sharp edges of the glass sheet are beveled by grinding and polishing.
- Cutting, edge machining, and other processing steps can introduce initial flaws, such as chips or cracks, at surfaces and edges of the glass sheet.
- Strength imperfections can originate from the initial flaws when the glass sheet is subject to tensile stress. Accordingly, initial flaws can compromise the strength of the glass sheet.
- a method of validating edge strength of a glass sheet comprises a first surface, a second surface opposing the first surface, a thickness defined between the first surface and the second surface, and at least one edge comprising an edge surface.
- the first surface and the second surface intersect the edge surface of the at least one edge.
- the method comprises a step (I) of noncontactually thermally loading the glass sheet to subject at least a portion of the at least one edge to a tensile stress.
- the method also comprises a step (II) of determining whether the at least one edge has an edge strength below a predetermined level by detecting whether a resulting strength imperfection has originated in the glass sheet due to the noncontactual thermal loading of step (I).
- the tensile stress is a hoop stress.
- step (I) comprises producing at least one temperature gradient in the glass sheet.
- step (I) comprises producing at least one temperature gradient in the glass sheet, the temperature gradient emanating from a site on the glass sheet, the site being a distance from the edge surface.
- step (I) comprises producing at least one temperature gradient in the glass sheet, the temperature gradient emanating from a site on the glass sheet, the site having a position that changes based on translational motion of the glass sheet relative to a source of the noncontactual thermal loading.
- step (I) comprises delivering at least one focused infrared beam to at least one of the first and second surfaces of the glass sheet, the beam producing at least one temperature gradient in the glass sheet.
- step (I) comprises delivering (i) at least a first focused infrared beam to the first surface of the glass sheet and (ii) at least a second focused infrared beam to the second surface of the glass sheet, the at least first and second focused beams forming at least one pair of beams that are coincident with respect to the glass sheet.
- step (I) all of the at least one edge is progressively subjected to the tensile stress based on translational motion of the glass sheet relative to a source of the noncontactual thermal loading.
- the at least one edge comprises at least a first edge and a second edge opposing the first edge, and further wherein step (I) comprises independently noncontactually thermally loading the glass sheet to subject at least a portion of the first edge and at least a portion of the second edge to the tensile stress.
- the at least one edge comprises a complete perimeter of the glass sheet, and further wherein step (I) comprises noncontactually thermally loading the glass sheet to subject the complete perimeter to the tensile stress.
- step (I) comprises delivering at least one focused jet of gas to at least a portion of the at least one edge, the gas being colder than the at least one edge, the gas producing at least one temperature gradient in the glass sheet.
- the detecting of the resulting imperfection comprises a detection method selected from the group consisting of visual detection, optical detection, and acoustic detection.
- the method further comprises a step (III) of estimating the tensile stress based on an interference fit model of a heated inner cylinder and a non-heated outer cylinder, wherein: the inner cylinder corresponds to a site on the glass sheet from which a temperature gradient emanates and has an inner ring radius; the outer cylinder corresponds to a portion of the glass sheet surrounding the site and comprises an outer edge that intersects the at least one edge of the glass sheet and has an outer ring radius; the inner and outer cylinders being concentric and made from the glass sheet, in accordance with the equation:
- s t is the tangential stress at the outer edge of the outer cylinder
- ⁇ T is the temperature difference between the inner cylinder and the outer cylinder
- ⁇ is the coefficient of thermal expansion of the glass sheet
- E is the Young's modulus for the glass sheet
- a is the inner ring radius of the inner cylinder
- b is the outer ring radius of the outer cylinder.
- the method further comprises a step of shaping the at least one edge of the glass sheet prior to steps (I) and (II), wherein the glass sheet is of a predetermined size.
- the method further comprises a step of chemically strengthening the glass sheet prior to steps (I) and (II).
- the thickness defined between the first surface of the glass sheet and the second surface of the glass sheet is less than about 1 mm.
- the first aspect may be carried out alone or in combination with any one or more of the examples of the first aspect discussed above.
- a method of validating edge strength of a glass sheet wherein the glass sheet includes a first surface, a second surface opposing the first surface, a thickness defined between the first surface and the second surface, and at least one edge comprising an edge surface, wherein the first surface and the second surface intersect the edge surface of the at least one edge.
- the method comprises a step (I) of noncontactually thermally loading the glass sheet to produce at least one temperature gradient in the glass sheet.
- the temperature gradient emanates from a site on the glass sheet located a distance from the edge surface.
- the site has a position that changes based on translational motion of the glass sheet relative to a source of the noncontactual thermal loading.
- the temperature gradient subjects at least a portion of the at least one edge to a tensile stress.
- the method further includes a step (II) of determining whether the at least one edge has an edge strength below a predetermined level by detecting whether a resulting strength imperfection has originated in the glass sheet due to the noncontactual thermal loading of step (I).
- step (I) comprises delivering at least one focused infrared beam to at least one of the first and second surfaces of the glass sheet, the beam producing at least one temperature gradient in the glass sheet.
- step (I) comprises delivering (i) at least a first focused infrared beam to the first surface of the glass sheet and (ii) at least a second focused infrared beam to the second surface of the glass sheet, the at least first and second focused beams forming at least one pair of beams that are coincident with respect to the glass sheet.
- step (I) comprises delivering at least one focused jet of gas to at least a portion of the at least one edge, the gas being colder than the at least one edge, the gas producing at least one temperature gradient in the glass sheet.
- the second aspect may be carried out alone or in combination with any one or more of the examples of the second aspect discussed above.
- FIG. 1 is a schematic perspective view of part of an example glass sheet
- FIG. 2 is a flow chart of a method of validating edge strength of a glass sheet
- FIG. 3 is a schematic perspective view of part of an example glass sheet, also illustrating an infrared lamp and a cylinder of gas;
- FIG. 4 is a schematic perspective view of part of an example glass sheet and illustrates that tensile stress can be a hoop stress
- FIG. 5 is a schematic perspective view of part of an example glass sheet in translational motion, on a conveyor, relative to a source of noncontactual thermal loading;
- FIG. 6 is a schematic perspective view similar to FIG. 5 but further demonstrating a step of detecting whether a resulting strength imperfection has originated in the glass sheet due to a noncontactual thermal loading;
- FIG. 7 is a schematic perspective view of part of an example glass sheet, also illustrating focused infrared beams and a temperature gradient;
- FIG. 8 is a schematic perspective view of an example glass sheet, also illustrating two temperature gradients
- FIG. 9 is a flow chart of a method of validating edge strength of a glass sheet
- FIG. 10 is a schematic perspective view of an exemplary apparatus that can be used to validate edge strength of a glass sheet
- FIG. 11 is a diagram of compressive and tensile stress in psi induced following heating of an internal 0.8 inch (2 cm) diameter circular region of a 1.0 inch (2.54 cm) diameter disk to a temperature of 300° C. above that of the outer ring, in accordance with a finite-element thermomechanical model;
- FIG. 12 is a diagram of temperature distribution in ° C. of a glass sheet at 0.5 seconds after 35 watts have been absorbed on each side of the glass sheet, near a bull-nose edge thereof, with temperatures rising from a base of 25° C. to a maximum of 184° C.;
- FIG. 13 is a diagram of compressive and tensile stress in psi induced in the glass sheet as described in FIG. 12 , based on the temperature distribution thereof at 0.5 seconds after 35 watts have been absorbed on each side of the glass sheet, in accordance with a finite-element thermomechanical model.
- the glass sheet 10 can comprise a first surface 12 , a second surface 14 opposing the first surface 12 , a thickness 16 defined between the first surface 12 and the second surface 14 , and at least one edge 18 comprising an edge surface 20 , wherein the first surface 12 and the second surface 14 intersect the edge surface 20 of the at least one edge 18 .
- the glass sheet 10 can be made, for example, from soda-lime float glass or a specialty glass sheet.
- the glass sheet 10 can be, for example, a window glass sheet, an architectural glass sheet, an automotive glass sheet, an LCD glass sheet, or a photovoltaic panel glass sheet.
- the glass sheet 10 can be, for example, a CORNING® EAGLE XGTM AMLCD glass sheet, a CORNING® EAGLE XGTM Slim glass sheet, a CORNING® WILLOWTM glass sheet, or a CORNING® LOTUSTM glass sheet.
- the glass sheet 10 can be, for example, a stock glass sheet, e.g. a glass sheet ordered in a size intended to be cut to create a final size, or a cut size glass sheet, e.g. a glass sheet cut to a predetermined size, such as a final intended size.
- the glass sheet 10 can be a glass sheet that has been initially cut to size by a process including scoring, such as mechanical scoring, laser scoring, or the like, followed by separation.
- the glass sheet 10 can also be a glass sheet for which at least one edge thereof has been shaped and/or can be of a predetermined size.
- the glass sheet 10 can also be, for example a glass sheet that has been chemically strengthened, e.g. CORNING® GORILLA® Glass.
- the thickness 16 defined between the first surface 12 of the glass sheet 10 and the second surface 14 of the glass sheet 10 can be, for example, less than about 1 mm, e.g. less than about 0.7 mm, less than about 0.5 mm, or less than about 0.3 mm.
- the method can comprise a step (I) 201 of noncontactually thermally loading the glass sheet 10 to subject at least a portion 22 of the at least one edge 18 to a tensile stress.
- the noncontactual thermal loading of the glass sheet 10 to subject at least the portion 22 of the at least one edge 18 to a tensile stress can include generating a temperature difference between a portion 26 of the glass sheet 10 near the at least one edge 18 and the portion 22 of the at least one edge 18 , such that the temperature of the portion 26 near the at least one edge 18 is greater than the temperature of the portion 22 of the at least one edge 18 .
- the noncontactual thermal loading can be accomplished, for example, by heating the portion 26 of the glass sheet 10 near the at least one edge 18 , cooling the portion 22 of the at least one edge 18 , or both. This is in contrast, for example, to heating that is uniform across a glass sheet 10 and that thus would not generate a temperature difference across the glass sheet 10 .
- a temperature difference between the portion 26 and the portion 22 wherein the portion 26 is at higher temperature than the portion 22 , subjects the portion 26 to a compressive stress, and correspondingly subjects the portion 22 to a tensile stress.
- the at least a portion 22 of the at least one edge 18 can be part or all of the at least one edge 18 .
- the noncontactual thermal loading is carried out by use of a source 30 of thermal loading that does not come in direct contact with the glass sheet 10 .
- a source 30 of thermal loading that does not come in direct contact with the glass sheet 10 .
- Exemplary approaches for such noncontactual thermal loading include use of an infrared lamp (e.g., broadband light bulb, narrowband lasers, etc.) as the source 30 of thermal loading, for example to deliver a focused infrared beam 34 to a portion 26 of the glass sheet 10 near the at least one edge 18 , thereby heating the portion 26 relative to at least a portion 22 of the at least one edge 18 , without the infrared lamp 32 coming in contact with the glass sheet 10 .
- an infrared lamp e.g., broadband light bulb, narrowband lasers, etc.
- Exemplary approaches for noncontactual thermal loading also include use of a cylinder 36 of gas as the source 30 of thermal loading, for example to deliver a focused jet 38 of cold gas to at least a portion 22 of the at least one edge 18 , thereby cooling the portion 22 relative to a portion 26 of the glass sheet 10 near the at least one edge 18 , without the cylinder 36 coming in contact with the glass sheet 10 .
- a cylinder 36 of gas as the source 30 of thermal loading
- a focused jet 38 of cold gas to at least a portion 22 of the at least one edge 18 , thereby cooling the portion 22 relative to a portion 26 of the glass sheet 10 near the at least one edge 18 , without the cylinder 36 coming in contact with the glass sheet 10 .
- This is in contrast, for example, to heating a glass sheet 10 in an oven, the glass sheet 10 being on a thermally conductive rack, as this would result in thermal loading concentrated at points of contact between the rack and the glass sheet 10 .
- thermally loading the glass sheet 10 noncontactually decreases the risk that new initial flaws may be introduced at a surface of the glass sheet 10 inadvertently based on physical contact, which may otherwise result in a deleterious weakening of the glass sheet 10 and a decrease in the edge strength thereof.
- the tensile stress can be a hoop stress. This can be accomplished, for example, by generating a temperature difference between a portion 26 of the glass sheet 10 near the at least one edge 18 and a portion 22 of the at least one edge 18 , the portion 26 being at higher temperature than the portion 22 , wherein the portion 26 has the shape of a cylinder 40 , the first end 42 of the cylinder being located at the first surface 12 of the glass sheet 10 , the second end 44 of the cylinder being located at the second surface 14 of the glass sheet 10 , and the body 46 of the cylinder extending through the glass sheet 10 therebetween, and wherein the portion 26 is located a distance from, i.e. does not intersect, the at least one edge 18 .
- the resulting tensile stress is a hoop stress that is exerted circumferentially from the portion 26 .
- the resulting tensile stress is also similar in part to tensile stresses to which glass sheets are subjected during typical uses, and thus can be used to validate edge strength that has a practical relevance.
- step (I) can comprise producing at least one temperature gradient 50 in the glass sheet 10 .
- the temperature gradient can be directed from a portion 26 of the glass sheet 10 near the at least one edge 18 to at least a portion 22 of the at least one edge 18 , the portion 26 having a higher temperature than the portion 22 , and can reflect the rate at which the temperature of the glass sheet changes therebetween.
- the temperature gradient 50 can, for example, emanate from a site 52 on the glass sheet 10 , e.g. a spot, circle, or the like, that is heated, the site 52 being a distance from, i.e. not intersecting, the at least one edge 18 .
- the site 52 can, for example, have a position that changes based on translational motion of the glass sheet 10 relative to the source 30 of the noncontactual thermal loading. This can be based, for example, on the glass sheet 10 being in motion, e.g. on a conveyor 54 , while the source 30 of noncontactual thermal loading is not. Alternatively, the source 30 of noncontactual thermal loading can be in motion, while the glass sheet 10 is not. As still another alternative, both the glass sheet 10 and the source 30 of noncontactual thermal loading can be in motion.
- the translational motion of the glass sheet 10 relative to the source 30 of the noncontactual thermal loading can provide a simple basis for subjecting at least a portion 22 of the at least one edge 18 , e.g. part or all of the at least one edge 18 , to a tensile stress, thereby allowing validation of edge strength with respect to the at least one edge 18 .
- all of the at least one edge 18 can be progressively subjected to the tensile stress, based on translational motion of the glass sheet 10 relative to the source 30 of the noncontactual thermal loading.
- all of the at least one edge 18 can be subjected to a peak tensile stress, thereby allowing validation of edge strength with respect to all of the at least one edge 18 .
- step (I) can comprise delivering at least one focused infrared beam 34 to at least one of the first and second surfaces 12 and 14 of the glass sheet 10 , the beam 34 producing at least one temperature gradient 50 in the glass sheet 10 .
- the glass sheet 10 can be positioned in the path of a focused infrared beam 34 , with the first surface 12 of the glass sheet 10 proximal to the beam 34 , such that the beam 34 is delivered to the glass sheet 10 at the first surface 12 thereof.
- the glass sheet 10 can be positioned similarly except that the second surface 14 is proximal to the beam 34 , such that the beam 34 is delivered to the glass sheet 10 at the second surface 14 thereof.
- the glass sheet 10 can be oriented such that the first and/or second surfaces 12 and 14 thereof are substantially or precisely normal to the beam 34 , although other orientations can also be used.
- the glass sheet 10 can be heated with a high degree of precision, both in terms of intensity and location, at the first and second surfaces 12 and 14 at which the beam 34 enters and exits the glass sheet 10 , and internally therebetween (e.g., by conduction from the surfaces being heated by the beam), along a path defined by the path of the beam 34 .
- the focused infrared beam 34 can heat the glass sheet 10 rapidly, not just from the first and second surfaces 12 and 14 of the glass sheet 10 , but also conducting from the surfaces internally, along the path of the beam 34 , allowing the at least one edge 18 to be subjected to a tensile stress rapidly, not just at the first and second surfaces 12 and 14 of the glass sheet 10 , but also internally with respect to the glass sheet 10 .
- step (I) can also comprise delivering (i) at least a first focused infrared beam 60 to the first surface 12 of the glass sheet 10 and (ii) at least a second focused infrared beam 62 to the second surface 14 of the glass sheet 10 , the at least first and second focused beams 60 and 62 forming at least one pair of beams 64 that are coincident with respect to the glass sheet 10 .
- the glass sheet 10 can be positioned in the paths of both a first focused infrared beam 60 and a second focused infrared beam 62 , with the first and second surfaces 12 and 14 of the glass sheet 10 proximal to the first and second beams 60 and 62 , respectively, such that the first and second beams 60 and 62 are delivered to the glass sheet 10 at the first and second surfaces 12 and 14 , respectively.
- the glass sheet 10 can also be positioned similarly, except with the first surface 12 proximal to the second beam 62 , and vice versa.
- the glass sheet 10 can be oriented such that the first and second surfaces 12 and 14 thereof are substantially or precisely normal to the first and second beams 60 and 62 , and particularly such that the first and second beams 60 and 62 form a pair of beams 64 that are coincident, e.g. entirely overlapping, with respect to the glass sheet 10 .
- the glass sheet 10 can be heated with an even higher degree of precision, at the first and second surfaces 12 and 14 at which the beams 60 and 62 enter and exit the glass sheet 10 , and internally therebetween, along a path defined by the path of the pair of beams 64 .
- the pair of infrared beams 64 can heat the glass sheet 10 not just rapidly, but also symmetrically, with respect to the first and second surfaces 12 and 14 , along the path of the pair of beams 64 , allowing the at least one edge 18 to be subjected to a tensile stress not just rapidly, but also with a high degree of stress uniformity.
- the method of validating edge strength of the glass sheet 10 can also be carried out with respect to a glass sheet 10 comprising a plurality of edges 70 , e.g. by validating edge strength along two or more of the plurality of edges 70 .
- the method can be carried out wherein the at least one edge 18 comprises at least a first edge 72 and a second edge 74 opposing the first edge 72 , and further wherein step (I) comprises independently noncontactually thermally loading the glass sheet 10 to subject at least a portion 76 of the first edge 72 and at least a portion 78 of the second edge 74 to the tensile stress.
- step (I) can comprise noncontactually thermally loading the glass sheet 10 to subject the first edge 72 to a first tensile stress, and independently, e.g. previously, subsequently, or simultaneously and separately, noncontactually thermally loading the glass sheet 10 to subject the second edge 74 to a second tensile stress.
- the first and second tensile stresses can be of the same magnitude or of different magnitudes, as appropriate.
- the noncontactual thermal loading can be carried out to subject additional edges 70 of the glass sheet 10 , e.g. a third edge 90 and a fourth edge 92 opposing the third edge 90 , to the tensile stress independently.
- translational motion of the glass sheet 10 relative to the sources 30 of the noncontactual thermal loading can be carried out to subject as much as all of the edges 70 to the tensile stress.
- the method can be carried out wherein the at least one edge 18 comprises a complete perimeter 94 of the glass sheet 10 , and further wherein step (I) comprises noncontactually thermally loading the glass sheet 10 to subject the complete perimeter 94 to the tensile stress.
- step (I) can also comprise delivering at least one focused jet 38 of gas along a portion 22 of the at least one edge 18 , the gas being colder than the at least one edge, the gas producing at least one temperature gradient in the glass sheet 10 .
- the gas can be, for example, nitrogen vapor obtained by evaporation of liquid nitrogen, among others, and can be directed specifically at the at least one edge 18 , e.g. by use of a nozzle.
- the method of validating edge strength of the glass sheet 10 can also comprise a step (II) 202 of determining whether the at least one edge 18 has an edge strength below a predetermined level by detecting whether a resulting strength imperfection 28 has originated in the glass sheet 10 due to the noncontactual thermal loading of step (I).
- strength imperfections 28 can originate from initial flaws 29 when a glass sheet 10 is subjected to tensile stress, and accordingly initial flaws 29 can compromise the strength of the glass sheet 10 .
- a resulting strength imperfection 28 can originate in the glass sheet 10 from the initial flaw 29 .
- the resulting strength imperfection 28 can be a crack, fissure, fracture, breakage, or the like, can vary from microscopic to macroscopic in scale, and can further degrade edge strength of the glass sheet 10 relative to initial flaw 29 , resulting for example in cracking and/or breaking of the glass sheet 10 .
- the resulting strength imperfection will form if at least one edge 18 of the glass sheet 10 is subjected to a tensile stress that exceeds the corresponding edge strength, and will do so essentially immediately or very soon after formation of the temperature gradient.
- the tensile strength to which the at least one edge 18 is subjected can be controlled to match a corresponding edge strength of a predetermined level.
- the edge strength of a predetermined level can be, for example, an edge strength that is expected for the glass sheet 10 (e.g. based on its composition and dimensions in the absence of any initial flaws 29 , and/or considering edge grinding or other edge finishing processes performed on the edge of the glass) and edge strength that is desired for the glass sheet 10 , e.g.
- step (I) detection of the presence of a resulting strength imperfection 28 following the noncontactual thermal loading of step (I) can be indicative of the at least one edge 18 having an edge strength below a predetermined level.
- the absence of a resulting strength imperfection 28 following the noncontactual thermal loading of step (I) can be indicative of the at least one edge 18 not having an edge strength below a predetermined level.
- the detecting of the resulting strength imperfection 28 can comprise, for example, visual detection 120 , optical detection 122 , or acoustic detection 124 .
- Visual detection 120 can be done manually, e.g. based on an individual inspecting a glass sheet 10 for a resulting strength imperfection 28 that is on a macroscopic scale, e.g. following step (I), as shown in FIG. 2 .
- magnifying lenses may be used to help allow visual inspection.
- Optical detection 122 can be done automatically, e.g.
- Acoustic detection 124 can also be done manually, e.g., based on an individual listening to the glass sheet 10 for noises typical of strength imperfection formation. Acoustic detection 124 can also be carried out automatically, e.g. based on use of a microphone to detect sounds generated during origination of a resulting strength imperfection 28 , e.g. during step (I), as shown in FIG. 9 .
- Automatic acoustic monitoring can have the advantage of detecting sounds with frequencies that may be outside of the audible range of a human, thereby possibly making manual acoustic detection undesirable in example applications.
- the method of validating edge strength of the glass sheet 10 can also comprise a step (III) 203 of estimating the tensile stress based on an interference fit model of a heated inner cylinder and a non-heated outer cylinder.
- the inner cylinder corresponds to a site on a glass sheet from which a temperature gradient emanates and has an inner ring radius.
- the outer cylinder corresponds to a portion of the glass sheet surrounding the site and comprises an outer edge that intersects the at least one edge of the glass sheet and has an outer ring radius.
- the inner and outer cylinders are concentric and made from the glass sheet.
- the tensile stress is estimated in accordance with the equation:
- s t is the tangential stress at the outer edge of the outer cylinder
- ⁇ T is the temperature difference between the inner cylinder and the outer cylinder
- ⁇ is the coefficient of thermal expansion of the glass sheet
- E is the Young's modulus for the glass sheet
- a is the inner ring radius of the inner cylinder
- b is the outer ring radius of the outer cylinder.
- This interference fit model can be used to estimate tensile stress during noncontactual thermal loading of the glass sheet.
- the inner ring radius of the inner cylinder can be fixed or varied, e.g. by fixing or varying the diameter of the infrared beam.
- the outer ring radius of the outer cylinder also can be fixed or varied, e.g. by fixing or varying the position of the infrared beam relative to the at least one edge.
- the temperature difference between the inner cylinder and the outer cylinder also can be fixed or varied, e.g.
- the interference fit model thus can be used to estimate tensile stress during a specific set of conditions, e.g. fixed ⁇ T, a, and b, or under a range of conditions, e.g. varying ⁇ T, a, and/or b.
- the interference fit model can also be used to match the noncontactual thermal loading of a particular glass sheet with the edge strength expected, desired, or required for the glass sheet, e.g.
- the noncontactual thermal loading is appropriate to subject the at least one edge of the glass sheet to a tensile stress that can cause a resulting strength imperfection to originate in the glass sheet if the at least one edge has an edge strength below a predetermined level.
- the method of validating edge strength of the glass sheet 10 can be applied during manufacture of glass sheets 10 , e.g. for purposes of quality control.
- the method can further comprise a step 199 of shaping the at least one edge 18 of the glass sheet 10 prior to steps (I) and (II), wherein the glass sheet 10 is of a predetermined size.
- cutting, edge machining, and other processing steps can introduce initial flaws 29 , such as chips or cracks, at surfaces and edges of the glass sheet.
- the method also can further comprise a step 200 of chemically strengthening the glass sheet 10 prior to steps (I) and (II).
- steps (I) and (II) subsequent to chemically strengthening the glass sheet 10 , the effectiveness of the chemical strengthening in particular can be confirmed.
- the method also can be applied to validate edge strength of pluralities of glass sheets 10 corresponding to a production batch, e.g. all of the glass sheets 10 that have been manufactured in a particular production run, cut to a particular predetermined size, and finished, for purposes of immediate and efficient edge strength proof testing based not on statistical sampling but rather direct testing of each glass sheet 10 .
- an exemplary apparatus 100 can be used to validate edge strength during manufacture of glass sheets 10 , e.g. downstream from an edge finishing station, and to do so with respect to the entire perimeter 94 of a glass sheet 10 having four edges 72 , 74 , 90 , and 92 .
- the apparatus 100 can comprise first and second pairs of stationary infrared lamps 102 and 104 and a conveyor 106 for glass sheets 10 , one member of each of the first and second pairs of infrared lamps 102 and 104 above the conveyor 106 and the other member of each of the first and second pairs of infrared lamps 102 and 104 below.
- the apparatus 100 can also comprise third and fourth pairs of mobile infrared lamps 108 and 110 based on attachment thereof to gantries 112 , again with one member of each of the first and second pairs of infrared lamps 108 and 110 above the conveyor 106 and the other member of each of the first and second pairs of infrared lamps 108 and 110 below.
- the first and second edges 72 and 74 of the glass sheet 10 that are oriented parallel to the direction of translation of the glass sheet 10 are noncontactually thermally loaded by infrared beams 34 from the first and second pairs of stationary infrared lamps 102 and 104 , respectively, as discussed above.
- the third and fourth edges 90 and 92 of the glass sheet 10 that are oriented normal to the direction of translation of the glass sheet 10 are noncontactually thermally loaded by infrared beams 34 from the third and fourth pairs of mobile infrared lamps 108 and 110 , respectively, based on the conveyors 106 moving translationally in sequence with, but perpendicular to, the translational motion of the glass sheet 10 .
- the intensity of pairs of infrared lamps 102 , 104 , 108 , and 110 can be adjusted as a function of speed of translation of the glass sheet 10 to achieve heating of portions of the glass sheet 10 near the edges 72 , 74 , 90 , and 92 to desired peak temperatures by the infrared beams 34 , resulting in a corresponding peak tensile stress on the edges 72 , 74 , 90 , and 92 of the glass sheet 10 .
- Peak tensile stress can be adjusted in order to define edge failure stress probability distributions as a function of edge processing conditions. Once probability distributions are known, the apparatus 100 can be set to monitor additional glass sheets 10 to assure product quality.
- Alternatives such as an apparatus that includes pairs of first and second stationary infrared lamps 102 and 104 but not the pairs of third and fourth mobile infrared lamps 108 and 110 can also be used to validate edge strength along the entire perimeter 94 of a glass sheet 10 having four edges 72 , 74 , 90 , and 92 , for example by using the apparatus to validate edge strength with respect to the first and second edges 72 and 74 of the glass sheet 10 , then rotating the glass sheet 10 by 90° with respect to the apparatus, and then using the apparatus to validate edge strength with respect to the third and fourth edges 90 and 92 of the glass sheet 10 .
- the physical basis for thermal loading of a glass sheet can be quantitatively described by formulas that can be derived from the general case of concentric cylinders with an interference fit, i.e. an interference fit model.
- the interference is generated between an inner cylinder at an elevated temperature which thermally expands and is constrained by an outer cylinder at a cooler temperature. The result is to create compressive tangential stress in the inner cylinder and tensile tangential stress in the outer cylinder, as shown with respect to a finite-element thermomechanical model in FIG. 11 .
- s t is the tangential stress (e.g. psi) at the outer edge of the outer ring
- ⁇ T e.g. ° C.
- ⁇ is the coefficient of thermal expansion (e.g. ° C. ⁇ 1 ) of the glass sheet
- E is the Young's modulus (e.g. psi) for the glass sheet
- a is the inner heated ring radius (e.g. inches); and
- b is the outer ring radius (e.g. inches).
- the interference fit model can be used to estimate the tensile stress to which an edge of glass sheet is subjected as shown in the following example.
- a 1.0-inch diameter, 0.7-millimeter thick disk of CORNING® EAGLE XGTM alkaline earth boro-aluminosilicate glass has a centered circular portion having a diameter of 0.8 inches (2 cm) heated to a temperature of 300° C. above that of its outer rim.
- the coefficient of thermal expansion ⁇ is 31.7 ⁇ 10 ⁇ 7 ° C. ⁇ 1 and the Young's modulus E is 10.7 ⁇ 10 6 psi (7.5 ⁇ 10 5 kgf/cm 2 ).
- the cool outer edge of the disk will be under a tensile tangential stress of about 6,512 psi (457.8 kgf/cm 2 ).
- Those parameters applied to the finite-element thermomechanical model predicted 6,247 psi (439.2 kgf/cm 2 ), in good agreement.
- FIG. 12 illustrates a heated circular region of a glass sheet next to its edge, as a diagram of temperature distribution of the glass sheet at 0.5 seconds after 35 watts have been absorbed on each side of the glass sheet, near a bull-nose edge thereof, with temperatures rising from a base of 25° C. to a maximum of 184° C.
- FIG. 13 illustrates the resulting compressive and tensile stress, in accordance with a finite-element thermomechanical model. The equation above provides an estimate of the tensional stress load at the edge similar to that modeled in FIG. 13 , 5,390 psi (379 kgf/cm 2 ) versus 6,250 psi (439.4 kgf/cm 2 ), respectively.
- An infrared lamp with optics to focus its output beam down to a spot of a particular size can be used to heat a circular portion of the glass. If two such systems are located on either side of the glass sheet so that the spots are coincident upon the same glass area, fast and uniform heating through the thickness of the glass is possible. Temperature rise in the heated portion of glass will depend upon the lamp output power, the spectral power density of the lamp through the infrared wavelength interval, the absorption spectrum of the glass material through the same infrared wavelength interval, and the time of exposure. Of these four variables, the two of lamp output power and exposure time are easily varied and so these become the primary controls in order to achieve a specific temperature, and thus stress, rise.
- the methods disclosed herein can provide an efficient and non-destructive validation of edge strength of a glass sheet.
- Noncontactually thermally loading the glass sheet allows loading of at least one edge of a glass sheet with a desired level of tensile stress, thus providing a validation of edge strength of at least part of the at least one edge.
- all of the at least one edge of the glass sheet can be progressively subjected to the tensile stress, thus providing a validation of edge strength of all of the at least one edge.
- the at least one edge comprises a complete perimeter of the glass sheet, a validation of the edge strength of the complete perimeter can be obtained.
- determining whether the at least one edge has an edge strength below a predetermined level by detecting whether a resulting strength imperfection has originated in the glass sheet due to the noncontactual thermal loading provides a proof-test for edge strength, such that if no resulting strength imperfection has originated, it can be concluded that the strength of the edge is sufficiently high.
- the methods allow for exposure of every glass sheet to a desired level of stress for purposes of real-time process feedback and product quality assurance, without destruction of the glass sheets having an edge strength that is sufficiently high. The methods thus can provide beneficial real-time feedback into the edge finishing process.
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Abstract
Description
- The present invention relates generally to methods of validating edge strength and, more particularly, to methods of validating edge strength of a glass sheet.
- Glass sheets are component in products such as architectural and automotive windows, liquid crystal display (LCD) modules, and photovoltaic (PV) panels. For these applications, a glass sheet is typically cut to size, and then resulting sharp edges of the glass sheet are beveled by grinding and polishing. Cutting, edge machining, and other processing steps can introduce initial flaws, such as chips or cracks, at surfaces and edges of the glass sheet. Strength imperfections can originate from the initial flaws when the glass sheet is subject to tensile stress. Accordingly, initial flaws can compromise the strength of the glass sheet.
- The following presents a simplified summary of the disclosure in order to provide a basic understanding of some example aspects described in the detailed description.
- In a first aspect, a method of validating edge strength of a glass sheet is provided. The glass sheet comprises a first surface, a second surface opposing the first surface, a thickness defined between the first surface and the second surface, and at least one edge comprising an edge surface. The first surface and the second surface intersect the edge surface of the at least one edge. The method comprises a step (I) of noncontactually thermally loading the glass sheet to subject at least a portion of the at least one edge to a tensile stress. The method also comprises a step (II) of determining whether the at least one edge has an edge strength below a predetermined level by detecting whether a resulting strength imperfection has originated in the glass sheet due to the noncontactual thermal loading of step (I).
- In one example of the first aspect, the tensile stress is a hoop stress.
- In another example of the first aspect, step (I) comprises producing at least one temperature gradient in the glass sheet.
- In still another example of the first aspect, step (I) comprises producing at least one temperature gradient in the glass sheet, the temperature gradient emanating from a site on the glass sheet, the site being a distance from the edge surface.
- In yet another example of the first aspect, step (I) comprises producing at least one temperature gradient in the glass sheet, the temperature gradient emanating from a site on the glass sheet, the site having a position that changes based on translational motion of the glass sheet relative to a source of the noncontactual thermal loading.
- In a further example of the first aspect, step (I) comprises delivering at least one focused infrared beam to at least one of the first and second surfaces of the glass sheet, the beam producing at least one temperature gradient in the glass sheet.
- In another example of the first aspect, step (I) comprises delivering (i) at least a first focused infrared beam to the first surface of the glass sheet and (ii) at least a second focused infrared beam to the second surface of the glass sheet, the at least first and second focused beams forming at least one pair of beams that are coincident with respect to the glass sheet.
- In still another example of the first aspect, during step (I) all of the at least one edge is progressively subjected to the tensile stress based on translational motion of the glass sheet relative to a source of the noncontactual thermal loading.
- In yet another example of the first aspect, the at least one edge comprises at least a first edge and a second edge opposing the first edge, and further wherein step (I) comprises independently noncontactually thermally loading the glass sheet to subject at least a portion of the first edge and at least a portion of the second edge to the tensile stress.
- In a further example of the first aspect, the at least one edge comprises a complete perimeter of the glass sheet, and further wherein step (I) comprises noncontactually thermally loading the glass sheet to subject the complete perimeter to the tensile stress.
- In still a further example of the first aspect, step (I) comprises delivering at least one focused jet of gas to at least a portion of the at least one edge, the gas being colder than the at least one edge, the gas producing at least one temperature gradient in the glass sheet.
- In yet a further example of the first aspect, during step (II) the detecting of the resulting imperfection comprises a detection method selected from the group consisting of visual detection, optical detection, and acoustic detection.
- In another example of the first aspect, the method further comprises a step (III) of estimating the tensile stress based on an interference fit model of a heated inner cylinder and a non-heated outer cylinder, wherein: the inner cylinder corresponds to a site on the glass sheet from which a temperature gradient emanates and has an inner ring radius; the outer cylinder corresponds to a portion of the glass sheet surrounding the site and comprises an outer edge that intersects the at least one edge of the glass sheet and has an outer ring radius; the inner and outer cylinders being concentric and made from the glass sheet, in accordance with the equation:
-
s t =+ΔTαE(a 2 /b 2) - in which st is the tangential stress at the outer edge of the outer cylinder; ΔT is the temperature difference between the inner cylinder and the outer cylinder; α is the coefficient of thermal expansion of the glass sheet; E is the Young's modulus for the glass sheet; a is the inner ring radius of the inner cylinder; and b is the outer ring radius of the outer cylinder.
- In still another example of the first aspect, the method further comprises a step of shaping the at least one edge of the glass sheet prior to steps (I) and (II), wherein the glass sheet is of a predetermined size.
- In yet another example of the first aspect, the method further comprises a step of chemically strengthening the glass sheet prior to steps (I) and (II).
- In a further example of the first aspect, the thickness defined between the first surface of the glass sheet and the second surface of the glass sheet is less than about 1 mm.
- The first aspect may be carried out alone or in combination with any one or more of the examples of the first aspect discussed above.
- In a second aspect, a method of validating edge strength of a glass sheet is provided wherein the glass sheet includes a first surface, a second surface opposing the first surface, a thickness defined between the first surface and the second surface, and at least one edge comprising an edge surface, wherein the first surface and the second surface intersect the edge surface of the at least one edge. The method comprises a step (I) of noncontactually thermally loading the glass sheet to produce at least one temperature gradient in the glass sheet. The temperature gradient emanates from a site on the glass sheet located a distance from the edge surface. The site has a position that changes based on translational motion of the glass sheet relative to a source of the noncontactual thermal loading. The temperature gradient subjects at least a portion of the at least one edge to a tensile stress. The method further includes a step (II) of determining whether the at least one edge has an edge strength below a predetermined level by detecting whether a resulting strength imperfection has originated in the glass sheet due to the noncontactual thermal loading of step (I).
- In one example of the second aspect, step (I) comprises delivering at least one focused infrared beam to at least one of the first and second surfaces of the glass sheet, the beam producing at least one temperature gradient in the glass sheet.
- In another example of the second aspect, step (I) comprises delivering (i) at least a first focused infrared beam to the first surface of the glass sheet and (ii) at least a second focused infrared beam to the second surface of the glass sheet, the at least first and second focused beams forming at least one pair of beams that are coincident with respect to the glass sheet.
- In still another example of the second aspect, step (I) comprises delivering at least one focused jet of gas to at least a portion of the at least one edge, the gas being colder than the at least one edge, the gas producing at least one temperature gradient in the glass sheet.
- The second aspect may be carried out alone or in combination with any one or more of the examples of the second aspect discussed above.
- These and other features, aspects and advantages of the present disclosure are better understood when the following detailed description is read with reference to the accompanying drawings, in which:
-
FIG. 1 is a schematic perspective view of part of an example glass sheet; -
FIG. 2 is a flow chart of a method of validating edge strength of a glass sheet; -
FIG. 3 is a schematic perspective view of part of an example glass sheet, also illustrating an infrared lamp and a cylinder of gas; -
FIG. 4 is a schematic perspective view of part of an example glass sheet and illustrates that tensile stress can be a hoop stress; -
FIG. 5 is a schematic perspective view of part of an example glass sheet in translational motion, on a conveyor, relative to a source of noncontactual thermal loading; -
FIG. 6 is a schematic perspective view similar toFIG. 5 but further demonstrating a step of detecting whether a resulting strength imperfection has originated in the glass sheet due to a noncontactual thermal loading; -
FIG. 7 is a schematic perspective view of part of an example glass sheet, also illustrating focused infrared beams and a temperature gradient; -
FIG. 8 is a schematic perspective view of an example glass sheet, also illustrating two temperature gradients; -
FIG. 9 is a flow chart of a method of validating edge strength of a glass sheet; -
FIG. 10 is a schematic perspective view of an exemplary apparatus that can be used to validate edge strength of a glass sheet; -
FIG. 11 is a diagram of compressive and tensile stress in psi induced following heating of an internal 0.8 inch (2 cm) diameter circular region of a 1.0 inch (2.54 cm) diameter disk to a temperature of 300° C. above that of the outer ring, in accordance with a finite-element thermomechanical model; -
FIG. 12 is a diagram of temperature distribution in ° C. of a glass sheet at 0.5 seconds after 35 watts have been absorbed on each side of the glass sheet, near a bull-nose edge thereof, with temperatures rising from a base of 25° C. to a maximum of 184° C.; and -
FIG. 13 is a diagram of compressive and tensile stress in psi induced in the glass sheet as described inFIG. 12 , based on the temperature distribution thereof at 0.5 seconds after 35 watts have been absorbed on each side of the glass sheet, in accordance with a finite-element thermomechanical model. - Methods will now be described more fully hereinafter with reference to the accompanying drawings in which example embodiments of the disclosure are shown. Whenever possible, the same reference numerals are used throughout the drawings to refer to the same or like parts. However, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.
- Example methods of the disclosure will be described with initial reference to the
glass sheet 10 illustrated inFIG. 1 . Theglass sheet 10 can comprise afirst surface 12, asecond surface 14 opposing thefirst surface 12, athickness 16 defined between thefirst surface 12 and thesecond surface 14, and at least oneedge 18 comprising anedge surface 20, wherein thefirst surface 12 and thesecond surface 14 intersect theedge surface 20 of the at least oneedge 18. Theglass sheet 10 can be made, for example, from soda-lime float glass or a specialty glass sheet. Theglass sheet 10 can be, for example, a window glass sheet, an architectural glass sheet, an automotive glass sheet, an LCD glass sheet, or a photovoltaic panel glass sheet. Among LCD glass sheets, theglass sheet 10 can be, for example, a CORNING® EAGLE XG™ AMLCD glass sheet, a CORNING® EAGLE XG™ Slim glass sheet, a CORNING® WILLOW™ glass sheet, or a CORNING® LOTUS™ glass sheet. Theglass sheet 10 can be, for example, a stock glass sheet, e.g. a glass sheet ordered in a size intended to be cut to create a final size, or a cut size glass sheet, e.g. a glass sheet cut to a predetermined size, such as a final intended size. Thus, for example, theglass sheet 10 can be a glass sheet that has been initially cut to size by a process including scoring, such as mechanical scoring, laser scoring, or the like, followed by separation. Theglass sheet 10 can also be a glass sheet for which at least one edge thereof has been shaped and/or can be of a predetermined size. Theglass sheet 10 can also be, for example a glass sheet that has been chemically strengthened, e.g. CORNING® GORILLA® Glass. Thethickness 16 defined between thefirst surface 12 of theglass sheet 10 and thesecond surface 14 of theglass sheet 10 can be, for example, less than about 1 mm, e.g. less than about 0.7 mm, less than about 0.5 mm, or less than about 0.3 mm. - Considering now the method of validating edge strength of the
glass sheet 10, as shown inFIG. 2 , with reference toFIG. 1 , the method can comprise a step (I) 201 of noncontactually thermally loading theglass sheet 10 to subject at least aportion 22 of the at least oneedge 18 to a tensile stress. The noncontactual thermal loading of theglass sheet 10 to subject at least theportion 22 of the at least oneedge 18 to a tensile stress can include generating a temperature difference between aportion 26 of theglass sheet 10 near the at least oneedge 18 and theportion 22 of the at least oneedge 18, such that the temperature of theportion 26 near the at least oneedge 18 is greater than the temperature of theportion 22 of the at least oneedge 18. The noncontactual thermal loading can be accomplished, for example, by heating theportion 26 of theglass sheet 10 near the at least oneedge 18, cooling theportion 22 of the at least oneedge 18, or both. This is in contrast, for example, to heating that is uniform across aglass sheet 10 and that thus would not generate a temperature difference across theglass sheet 10. Without wishing to be bound by theory, it is believed that a temperature difference between theportion 26 and theportion 22, wherein theportion 26 is at higher temperature than theportion 22, subjects theportion 26 to a compressive stress, and correspondingly subjects theportion 22 to a tensile stress. The at least aportion 22 of the at least oneedge 18 can be part or all of the at least oneedge 18. - As shown in
FIG. 3 , in accordance with step (I) the noncontactual thermal loading is carried out by use of asource 30 of thermal loading that does not come in direct contact with theglass sheet 10. Exemplary approaches for such noncontactual thermal loading include use of an infrared lamp (e.g., broadband light bulb, narrowband lasers, etc.) as thesource 30 of thermal loading, for example to deliver a focusedinfrared beam 34 to aportion 26 of theglass sheet 10 near the at least oneedge 18, thereby heating theportion 26 relative to at least aportion 22 of the at least oneedge 18, without theinfrared lamp 32 coming in contact with theglass sheet 10. Exemplary approaches for noncontactual thermal loading also include use of acylinder 36 of gas as thesource 30 of thermal loading, for example to deliver afocused jet 38 of cold gas to at least aportion 22 of the at least oneedge 18, thereby cooling theportion 22 relative to aportion 26 of theglass sheet 10 near the at least oneedge 18, without thecylinder 36 coming in contact with theglass sheet 10. This is in contrast, for example, to heating aglass sheet 10 in an oven, theglass sheet 10 being on a thermally conductive rack, as this would result in thermal loading concentrated at points of contact between the rack and theglass sheet 10. This is also in contrast, for example, to cooling at least oneedge 18 of aglass sheet 10 by submerging the at least oneedge 18 in a cold liquid, as this would involve direct contact between theglass sheet 10 and asource 30 of thermal loading, i.e. the cold liquid. Without wishing to be bound by theory, it is believed that thermally loading theglass sheet 10 noncontactually decreases the risk that new initial flaws may be introduced at a surface of theglass sheet 10 inadvertently based on physical contact, which may otherwise result in a deleterious weakening of theglass sheet 10 and a decrease in the edge strength thereof. - As shown in
FIG. 4 , the tensile stress can be a hoop stress. This can be accomplished, for example, by generating a temperature difference between aportion 26 of theglass sheet 10 near the at least oneedge 18 and aportion 22 of the at least oneedge 18, theportion 26 being at higher temperature than theportion 22, wherein theportion 26 has the shape of acylinder 40, thefirst end 42 of the cylinder being located at thefirst surface 12 of theglass sheet 10, thesecond end 44 of the cylinder being located at thesecond surface 14 of theglass sheet 10, and thebody 46 of the cylinder extending through theglass sheet 10 therebetween, and wherein theportion 26 is located a distance from, i.e. does not intersect, the at least oneedge 18. The resulting tensile stress is a hoop stress that is exerted circumferentially from theportion 26. The resulting tensile stress is also similar in part to tensile stresses to which glass sheets are subjected during typical uses, and thus can be used to validate edge strength that has a practical relevance. - As also shown in
FIG. 4 , step (I) can comprise producing at least onetemperature gradient 50 in theglass sheet 10. The temperature gradient can be directed from aportion 26 of theglass sheet 10 near the at least oneedge 18 to at least aportion 22 of the at least oneedge 18, theportion 26 having a higher temperature than theportion 22, and can reflect the rate at which the temperature of the glass sheet changes therebetween. Thetemperature gradient 50 can, for example, emanate from asite 52 on theglass sheet 10, e.g. a spot, circle, or the like, that is heated, thesite 52 being a distance from, i.e. not intersecting, the at least oneedge 18. By having thetemperature gradient 50 emanate from such asite 52 on theglass sheet 10, it is possible to maintain a high degree of control over the intensity and direction of the resulting tensile stress. - As shown in
FIG. 5 , thesite 52 can, for example, have a position that changes based on translational motion of theglass sheet 10 relative to thesource 30 of the noncontactual thermal loading. This can be based, for example, on theglass sheet 10 being in motion, e.g. on aconveyor 54, while thesource 30 of noncontactual thermal loading is not. Alternatively, thesource 30 of noncontactual thermal loading can be in motion, while theglass sheet 10 is not. As still another alternative, both theglass sheet 10 and thesource 30 of noncontactual thermal loading can be in motion. In each case, the translational motion of theglass sheet 10 relative to thesource 30 of the noncontactual thermal loading can provide a simple basis for subjecting at least aportion 22 of the at least oneedge 18, e.g. part or all of the at least oneedge 18, to a tensile stress, thereby allowing validation of edge strength with respect to the at least oneedge 18. Thus, for example, during step (I), all of the at least oneedge 18 can be progressively subjected to the tensile stress, based on translational motion of theglass sheet 10 relative to thesource 30 of the noncontactual thermal loading. By this approach, all of the at least oneedge 18 can be subjected to a peak tensile stress, thereby allowing validation of edge strength with respect to all of the at least oneedge 18. - Considering step (I) in additional detail, as shown in
FIG. 7 step (I) can comprise delivering at least one focusedinfrared beam 34 to at least one of the first andsecond surfaces glass sheet 10, thebeam 34 producing at least onetemperature gradient 50 in theglass sheet 10. For example, theglass sheet 10 can be positioned in the path of a focusedinfrared beam 34, with thefirst surface 12 of theglass sheet 10 proximal to thebeam 34, such that thebeam 34 is delivered to theglass sheet 10 at thefirst surface 12 thereof. Alternatively theglass sheet 10 can be positioned similarly except that thesecond surface 14 is proximal to thebeam 34, such that thebeam 34 is delivered to theglass sheet 10 at thesecond surface 14 thereof. Also for example, theglass sheet 10 can be oriented such that the first and/orsecond surfaces beam 34, although other orientations can also be used. By delivering the at least one focusedinfrared beam 34 to at least one of the first andsecond surfaces glass sheet 10, theglass sheet 10 can be heated with a high degree of precision, both in terms of intensity and location, at the first andsecond surfaces beam 34 enters and exits theglass sheet 10, and internally therebetween (e.g., by conduction from the surfaces being heated by the beam), along a path defined by the path of thebeam 34. For example, the focusedinfrared beam 34 can heat theglass sheet 10 rapidly, not just from the first andsecond surfaces glass sheet 10, but also conducting from the surfaces internally, along the path of thebeam 34, allowing the at least oneedge 18 to be subjected to a tensile stress rapidly, not just at the first andsecond surfaces glass sheet 10, but also internally with respect to theglass sheet 10. - As also shown in
FIG. 7 , step (I) can also comprise delivering (i) at least a first focusedinfrared beam 60 to thefirst surface 12 of theglass sheet 10 and (ii) at least a second focusedinfrared beam 62 to thesecond surface 14 of theglass sheet 10, the at least first and secondfocused beams beams 64 that are coincident with respect to theglass sheet 10. For example, theglass sheet 10 can be positioned in the paths of both a first focusedinfrared beam 60 and a second focusedinfrared beam 62, with the first andsecond surfaces glass sheet 10 proximal to the first andsecond beams second beams glass sheet 10 at the first andsecond surfaces glass sheet 10 can also be positioned similarly, except with thefirst surface 12 proximal to thesecond beam 62, and vice versa. Similarly as above, theglass sheet 10 can be oriented such that the first andsecond surfaces second beams second beams beams 64 that are coincident, e.g. entirely overlapping, with respect to theglass sheet 10. By so delivering the first and second focusedinfrared beams second surfaces glass sheet 10, theglass sheet 10 can be heated with an even higher degree of precision, at the first andsecond surfaces beams glass sheet 10, and internally therebetween, along a path defined by the path of the pair ofbeams 64. For example, the pair ofinfrared beams 64 can heat theglass sheet 10 not just rapidly, but also symmetrically, with respect to the first andsecond surfaces beams 64, allowing the at least oneedge 18 to be subjected to a tensile stress not just rapidly, but also with a high degree of stress uniformity. - As shown in
FIG. 8 , the method of validating edge strength of theglass sheet 10 can also be carried out with respect to aglass sheet 10 comprising a plurality ofedges 70, e.g. by validating edge strength along two or more of the plurality ofedges 70. For example, the method can be carried out wherein the at least oneedge 18 comprises at least afirst edge 72 and asecond edge 74 opposing thefirst edge 72, and further wherein step (I) comprises independently noncontactually thermally loading theglass sheet 10 to subject at least aportion 76 of thefirst edge 72 and at least aportion 78 of thesecond edge 74 to the tensile stress. In accordance with this example, step (I) can comprise noncontactually thermally loading theglass sheet 10 to subject thefirst edge 72 to a first tensile stress, and independently, e.g. previously, subsequently, or simultaneously and separately, noncontactually thermally loading theglass sheet 10 to subject thesecond edge 74 to a second tensile stress. This can be accomplished, for example, by heating afirst portion 80 of theglass sheet 10 near thefirst edge 72 and heating asecond portion 82 of theglass sheet 10 near thesecond edge 74, thus creating afirst temperature gradient 84 with respect to thefirst edge 72 and asecond temperature gradient 86 with respect to thesecond edge 74, the heating being carried out for example by use of pairs ofinfrared lamps 32 to generate pairs of focusedinfrared beams 64, each pair ofbeams 64 being coincident with respect to theglass sheet 10. This can also be accomplished, for example, by cooling at least aportion 76 of thefirst edge 72 and cooling at least aportion 78 of thesecond edge 74, the cooling being carried out for example by use ofjets 38 of gas. This can also be accomplished by a combination of these approaches, among others. In each case, the first and second tensile stresses can be of the same magnitude or of different magnitudes, as appropriate. In addition, the noncontactual thermal loading can be carried out to subjectadditional edges 70 of theglass sheet 10, e.g. athird edge 90 and afourth edge 92 opposing thethird edge 90, to the tensile stress independently. Furthermore, translational motion of theglass sheet 10 relative to thesources 30 of the noncontactual thermal loading can be carried out to subject as much as all of theedges 70 to the tensile stress. Thus, for example, the method can be carried out wherein the at least oneedge 18 comprises acomplete perimeter 94 of theglass sheet 10, and further wherein step (I) comprises noncontactually thermally loading theglass sheet 10 to subject thecomplete perimeter 94 to the tensile stress. - As can be seen in
FIG. 3 , step (I) can also comprise delivering at least onefocused jet 38 of gas along aportion 22 of the at least oneedge 18, the gas being colder than the at least one edge, the gas producing at least one temperature gradient in theglass sheet 10. The gas can be, for example, nitrogen vapor obtained by evaporation of liquid nitrogen, among others, and can be directed specifically at the at least oneedge 18, e.g. by use of a nozzle. - As shown in
FIG. 2 , with reference toFIG. 1 andFIG. 6 , the method of validating edge strength of theglass sheet 10 can also comprise a step (II) 202 of determining whether the at least oneedge 18 has an edge strength below a predetermined level by detecting whether a resultingstrength imperfection 28 has originated in theglass sheet 10 due to the noncontactual thermal loading of step (I). As noted above,strength imperfections 28 can originate frominitial flaws 29 when aglass sheet 10 is subjected to tensile stress, and accordinglyinitial flaws 29 can compromise the strength of theglass sheet 10. More particularly, when at least oneedge 18 of aglass sheet 10 that includes aninitial flaw 29 is subjected to a tensile stress, such as based on the noncontactual thermal loading of step (I), a resultingstrength imperfection 28 can originate in theglass sheet 10 from theinitial flaw 29. The resultingstrength imperfection 28 can be a crack, fissure, fracture, breakage, or the like, can vary from microscopic to macroscopic in scale, and can further degrade edge strength of theglass sheet 10 relative toinitial flaw 29, resulting for example in cracking and/or breaking of theglass sheet 10. The resulting strength imperfection will form if at least oneedge 18 of theglass sheet 10 is subjected to a tensile stress that exceeds the corresponding edge strength, and will do so essentially immediately or very soon after formation of the temperature gradient. Also, the tensile strength to which the at least oneedge 18 is subjected can be controlled to match a corresponding edge strength of a predetermined level. The edge strength of a predetermined level can be, for example, an edge strength that is expected for the glass sheet 10 (e.g. based on its composition and dimensions in the absence of anyinitial flaws 29, and/or considering edge grinding or other edge finishing processes performed on the edge of the glass) and edge strength that is desired for theglass sheet 10, e.g. based on testing new compositions for improved edge strengths, and/or an edge strength that is required for theglass sheet 10, e.g. based on subsequent intended uses of theglass sheet 10. Accordingly, detection of the presence of a resultingstrength imperfection 28 following the noncontactual thermal loading of step (I) can be indicative of the at least oneedge 18 having an edge strength below a predetermined level. Conversely, the absence of a resultingstrength imperfection 28 following the noncontactual thermal loading of step (I) can be indicative of the at least oneedge 18 not having an edge strength below a predetermined level. - Considering step (II) in more detail, as shown in
FIG. 6 the detecting of the resultingstrength imperfection 28 can comprise, for example,visual detection 120,optical detection 122, oracoustic detection 124.Visual detection 120 can be done manually, e.g. based on an individual inspecting aglass sheet 10 for a resultingstrength imperfection 28 that is on a macroscopic scale, e.g. following step (I), as shown inFIG. 2 . In further examples, magnifying lenses may be used to help allow visual inspection.Optical detection 122 can be done automatically, e.g. based on measurement of refraction and/or reflection patterns ofglass sheets 10 and corresponding electronic processing to identify those refraction patterns that are aberrant due to the presence of a resultingstrength imperfection 28, e.g. during step (I), as shown inFIG. 9 , or following step (I), as shown inFIG. 2 .Acoustic detection 124 can also be done manually, e.g., based on an individual listening to theglass sheet 10 for noises typical of strength imperfection formation.Acoustic detection 124 can also be carried out automatically, e.g. based on use of a microphone to detect sounds generated during origination of a resultingstrength imperfection 28, e.g. during step (I), as shown inFIG. 9 . Automatic acoustic monitoring can have the advantage of detecting sounds with frequencies that may be outside of the audible range of a human, thereby possibly making manual acoustic detection undesirable in example applications. - As shown in
FIG. 2 andFIG. 9 , the method of validating edge strength of theglass sheet 10 can also comprise a step (III) 203 of estimating the tensile stress based on an interference fit model of a heated inner cylinder and a non-heated outer cylinder. In accordance with this model, the inner cylinder corresponds to a site on a glass sheet from which a temperature gradient emanates and has an inner ring radius. The outer cylinder corresponds to a portion of the glass sheet surrounding the site and comprises an outer edge that intersects the at least one edge of the glass sheet and has an outer ring radius. The inner and outer cylinders are concentric and made from the glass sheet. The tensile stress is estimated in accordance with the equation: -
s t =+ΔTαE(a 2 /b 2) - in which st is the tangential stress at the outer edge of the outer cylinder; ΔT is the temperature difference between the inner cylinder and the outer cylinder; α is the coefficient of thermal expansion of the glass sheet; E is the Young's modulus for the glass sheet; a is the inner ring radius of the inner cylinder; and b is the outer ring radius of the outer cylinder.
- This interference fit model can be used to estimate tensile stress during noncontactual thermal loading of the glass sheet. For example, for noncontactual thermal loading of a glass sheet based on use of a focused infrared beam, the inner ring radius of the inner cylinder can be fixed or varied, e.g. by fixing or varying the diameter of the infrared beam. The outer ring radius of the outer cylinder also can be fixed or varied, e.g. by fixing or varying the position of the infrared beam relative to the at least one edge. The temperature difference between the inner cylinder and the outer cylinder also can be fixed or varied, e.g. by fixing or varying the intensity of an infrared beam used to heat a part of the glass sheet near the at least one edge of the glass sheet. The coefficient of thermal expansion of the glass sheet and the Young's modulus for the glass sheet depend on the composition of the glass sheet. The interference fit model thus can be used to estimate tensile stress during a specific set of conditions, e.g. fixed ΔT, a, and b, or under a range of conditions, e.g. varying ΔT, a, and/or b. The interference fit model can also be used to match the noncontactual thermal loading of a particular glass sheet with the edge strength expected, desired, or required for the glass sheet, e.g. by ensuring that the noncontactual thermal loading is appropriate to subject the at least one edge of the glass sheet to a tensile stress that can cause a resulting strength imperfection to originate in the glass sheet if the at least one edge has an edge strength below a predetermined level.
- The method of validating edge strength of the
glass sheet 10 can be applied during manufacture ofglass sheets 10, e.g. for purposes of quality control. For example, as shown inFIG. 2 andFIG. 9 the method can further comprise astep 199 of shaping the at least oneedge 18 of theglass sheet 10 prior to steps (I) and (II), wherein theglass sheet 10 is of a predetermined size. As noted above, cutting, edge machining, and other processing steps can introduceinitial flaws 29, such as chips or cracks, at surfaces and edges of the glass sheet. By carrying out steps (I) and (II) subsequent to shaping the at least oneedge 18 of theglass sheet 10 during manufacture, theglass sheet 10 can be subjected to immediate and efficient edge strength proof testing. The method also can further comprise astep 200 of chemically strengthening theglass sheet 10 prior to steps (I) and (II). By carrying out steps (I) and (II) subsequent to chemically strengthening theglass sheet 10, the effectiveness of the chemical strengthening in particular can be confirmed. The method also can be applied to validate edge strength of pluralities ofglass sheets 10 corresponding to a production batch, e.g. all of theglass sheets 10 that have been manufactured in a particular production run, cut to a particular predetermined size, and finished, for purposes of immediate and efficient edge strength proof testing based not on statistical sampling but rather direct testing of eachglass sheet 10. - As shown in
FIG. 10 , anexemplary apparatus 100 can be used to validate edge strength during manufacture ofglass sheets 10, e.g. downstream from an edge finishing station, and to do so with respect to theentire perimeter 94 of aglass sheet 10 having fouredges apparatus 100 can comprise first and second pairs of stationaryinfrared lamps conveyor 106 forglass sheets 10, one member of each of the first and second pairs ofinfrared lamps conveyor 106 and the other member of each of the first and second pairs ofinfrared lamps apparatus 100 can also comprise third and fourth pairs of mobileinfrared lamps gantries 112, again with one member of each of the first and second pairs ofinfrared lamps conveyor 106 and the other member of each of the first and second pairs ofinfrared lamps glass sheet 10 translates along theconveyor 106, the first andsecond edges glass sheet 10 that are oriented parallel to the direction of translation of theglass sheet 10 are noncontactually thermally loaded byinfrared beams 34 from the first and second pairs of stationaryinfrared lamps fourth edges glass sheet 10 that are oriented normal to the direction of translation of theglass sheet 10 are noncontactually thermally loaded byinfrared beams 34 from the third and fourth pairs of mobileinfrared lamps conveyors 106 moving translationally in sequence with, but perpendicular to, the translational motion of theglass sheet 10. The intensity of pairs ofinfrared lamps glass sheet 10 to achieve heating of portions of theglass sheet 10 near theedges infrared beams 34, resulting in a corresponding peak tensile stress on theedges glass sheet 10. Peak tensile stress can be adjusted in order to define edge failure stress probability distributions as a function of edge processing conditions. Once probability distributions are known, theapparatus 100 can be set to monitoradditional glass sheets 10 to assure product quality. - Alternatives, such as an apparatus that includes pairs of first and second stationary
infrared lamps infrared lamps entire perimeter 94 of aglass sheet 10 having fouredges second edges glass sheet 10, then rotating theglass sheet 10 by 90° with respect to the apparatus, and then using the apparatus to validate edge strength with respect to the third andfourth edges glass sheet 10. - The physical basis for thermal loading of a glass sheet can be quantitatively described by formulas that can be derived from the general case of concentric cylinders with an interference fit, i.e. an interference fit model. In accordance with the general case, the interference is generated between an inner cylinder at an elevated temperature which thermally expands and is constrained by an outer cylinder at a cooler temperature. The result is to create compressive tangential stress in the inner cylinder and tensile tangential stress in the outer cylinder, as shown with respect to a finite-element thermomechanical model in
FIG. 11 . - The tangential stress at the outer edge of the outer ring can be described by the following equation:
-
s t =+ΔTαE(a 2 /b 2) - where st is the tangential stress (e.g. psi) at the outer edge of the outer ring; ΔT (e.g. ° C.) is the temperature difference between the central and surrounding areas; α is the coefficient of thermal expansion (e.g. ° C.−1) of the glass sheet; E is the Young's modulus (e.g. psi) for the glass sheet; a is the inner heated ring radius (e.g. inches); and b is the outer ring radius (e.g. inches). Per convention, stresses in tension are assigned a positive value while those in compression are assigned a negative value.
- The interference fit model can be used to estimate the tensile stress to which an edge of glass sheet is subjected as shown in the following example. A 1.0-inch diameter, 0.7-millimeter thick disk of CORNING® EAGLE XG™ alkaline earth boro-aluminosilicate glass has a centered circular portion having a diameter of 0.8 inches (2 cm) heated to a temperature of 300° C. above that of its outer rim. The coefficient of thermal expansion α is 31.7×10−7° C.−1 and the Young's modulus E is 10.7×106 psi (7.5×105 kgf/cm2). According to the interference fit model, the cool outer edge of the disk will be under a tensile tangential stress of about 6,512 psi (457.8 kgf/cm2). Those parameters applied to the finite-element thermomechanical model predicted 6,247 psi (439.2 kgf/cm2), in good agreement.
- To first approximation the stress formula for the circular geometry of the disk example can be applied to portions of a rectangular glass sheet.
FIG. 12 illustrates a heated circular region of a glass sheet next to its edge, as a diagram of temperature distribution of the glass sheet at 0.5 seconds after 35 watts have been absorbed on each side of the glass sheet, near a bull-nose edge thereof, with temperatures rising from a base of 25° C. to a maximum of 184° C.FIG. 13 illustrates the resulting compressive and tensile stress, in accordance with a finite-element thermomechanical model. The equation above provides an estimate of the tensional stress load at the edge similar to that modeled inFIG. 13 , 5,390 psi (379 kgf/cm2) versus 6,250 psi (439.4 kgf/cm2), respectively. - An infrared lamp with optics to focus its output beam down to a spot of a particular size can be used to heat a circular portion of the glass. If two such systems are located on either side of the glass sheet so that the spots are coincident upon the same glass area, fast and uniform heating through the thickness of the glass is possible. Temperature rise in the heated portion of glass will depend upon the lamp output power, the spectral power density of the lamp through the infrared wavelength interval, the absorption spectrum of the glass material through the same infrared wavelength interval, and the time of exposure. Of these four variables, the two of lamp output power and exposure time are easily varied and so these become the primary controls in order to achieve a specific temperature, and thus stress, rise.
- The methods disclosed herein can provide an efficient and non-destructive validation of edge strength of a glass sheet. Noncontactually thermally loading the glass sheet allows loading of at least one edge of a glass sheet with a desired level of tensile stress, thus providing a validation of edge strength of at least part of the at least one edge. Moreover, when coupled with translational motion of the glass sheet relative to a source of the noncontactual thermal loading, all of the at least one edge of the glass sheet can be progressively subjected to the tensile stress, thus providing a validation of edge strength of all of the at least one edge. In addition, where the at least one edge comprises a complete perimeter of the glass sheet, a validation of the edge strength of the complete perimeter can be obtained. Furthermore, determining whether the at least one edge has an edge strength below a predetermined level by detecting whether a resulting strength imperfection has originated in the glass sheet due to the noncontactual thermal loading provides a proof-test for edge strength, such that if no resulting strength imperfection has originated, it can be concluded that the strength of the edge is sufficiently high. When carried out as part of a glass production system, the methods allow for exposure of every glass sheet to a desired level of stress for purposes of real-time process feedback and product quality assurance, without destruction of the glass sheets having an edge strength that is sufficiently high. The methods thus can provide beneficial real-time feedback into the edge finishing process.
- It will be apparent to those skilled in the art that various modifications and variations can be made to the present disclosure without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.
Claims (20)
s t =+ΔTαE(a 2 /b 2)
Priority Applications (6)
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US13/624,265 US8960014B2 (en) | 2012-09-21 | 2012-09-21 | Methods of validating edge strength of a glass sheet |
KR1020157006846A KR20150054843A (en) | 2012-09-21 | 2013-09-10 | Methods of validating edge strength of a glass sheet |
CN201380049070.XA CN104769427B (en) | 2012-09-21 | 2013-09-10 | The method of the edge strength of checking glass plate |
PCT/US2013/058967 WO2014046914A1 (en) | 2012-09-21 | 2013-09-10 | Methods of validating edge strength of a glass sheet |
JP2015533103A JP2015534062A (en) | 2012-09-21 | 2013-09-10 | Method to verify edge strength of glass sheet |
TW102133953A TW201418705A (en) | 2012-09-21 | 2013-09-18 | Methods of validating edge strength of a glass sheet |
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US13/624,265 US8960014B2 (en) | 2012-09-21 | 2012-09-21 | Methods of validating edge strength of a glass sheet |
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US20140083198A1 true US20140083198A1 (en) | 2014-03-27 |
US8960014B2 US8960014B2 (en) | 2015-02-24 |
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JP (1) | JP2015534062A (en) |
KR (1) | KR20150054843A (en) |
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US11549872B2 (en) | 2018-08-14 | 2023-01-10 | Corning Incorporated | Methods and apparatus for determining a crush strength of an edge |
DE102022127887A1 (en) | 2022-10-21 | 2024-05-02 | Endress+Hauser Conducta Gmbh+Co. Kg | Method for determining a glass quality indicator of a glass assembly and glass processing device for a glass assembly |
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US10613007B2 (en) * | 2015-03-13 | 2020-04-07 | Corning Incorporated | Edge strength testing methods and apparatuses |
CN105973715A (en) * | 2016-07-22 | 2016-09-28 | 江苏铁锚玻璃股份有限公司 | Differential pressure strength performance and breaking strength test device for airplane glass under temperature difference |
WO2020231681A1 (en) * | 2019-05-15 | 2020-11-19 | Corning Incorporated | System and method for edge strength testing with real-time stress visualization in ultra-thin glass panels |
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Also Published As
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CN104769427B (en) | 2016-10-19 |
KR20150054843A (en) | 2015-05-20 |
TW201418705A (en) | 2014-05-16 |
CN104769427A (en) | 2015-07-08 |
JP2015534062A (en) | 2015-11-26 |
US8960014B2 (en) | 2015-02-24 |
WO2014046914A1 (en) | 2014-03-27 |
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